关键词: 腐蚀损伤；分区防护；PCI；强化腐蚀试验；防腐设计

Abstract: To accurately identify differences in corrosion damage across various vehicle regions and achieve precise anti-corrosion design with cost optimization, this study systematically collected panel check index (PCI) data from four typical areas–roof, underbody, engine compartment, and passenger compartment-based on accelerated corrosion tests of passenger vehicles. Combined with the equivalent cumulative corrosion environment method, quantitative analysis and comparison of corrosion damage in each region were conducted. The test results show significant differences in corrosion damage across vehicle regions, with the damage level following the descending order: underbody>roof>engine compartment>passenger compartment. Notably, after 60 test cycles, the corrosion damage in the underbody reached 596.55, approximately 224 times that of the passenger compartment. Based on these findings, the paper further proposes a differentiated anti-corrosion design strategy for different zones, along with recommendations for materials, coatings, and structural improvements for high-risk areas. This research provides data support and methodological references for the reverse optimization of vehicle anti-corrosion design, contributing to the efficient allocation of anti-corrosion resources.

Key words: corrosion damage; zonal protection; PCI; accelerated corrosion test; anti-corrosion design